Iat DAEWOO LACETTI 2004 Service Repair Manual

SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR) 8B – 95
DAEWOO V–121 BL4
SIDE AIRBAG SENSOR
Removal and Installation Procedure
CAUTION : The sensing and diagnostic mod-
ule(SDM) can maintain sufficient voltage to
deploy the airbags and pretensioners for 1minute
after the ignition is OFF and the fuse has been re-
moved. If the airbags and pretensioners are not
disconnected, do not begin service until one
minute has passed after disconnecting power to
SDM. If the airbags are disconnected, service can
be executed immediately without waiting for
one–minute time period to expire. Failure to tem-
porarily disable the SIR during service can result
in unexpected deployment, personal injury and
unnecessary SIR repairs.
1. Disconnect the negative battery cable.
2. Remove the trim from B pillar.
3. Remove the side airbag sensor mounting bolts.
4. Remove the side airbag sensor.
5. Installation should follow the removal procedure in
the reverse order.
Tightening torque of the side airbag sensor mounting
bolts is 8 NSm (71 lb–in).
FRONT SEAT BELT PRETENSIONER
For removal and installation, refer to Section 8A, Seat
Belts.
AIRBAG MODULE DEPLOYMENT
(INSIDE OF VEHICLE)
Deploy the airbags before disposing them. If a vehicle
to be scrapped, the airbag may be deployed inside the
vehicle.
CAUTION : To avoid injury while deploying an air-
bag or a pretensioner in the vehicle, observe the
following precaution :
S Before deploying the airbags, remove all loose ob-
jects from the airbag’s expansion area.
S Deploy the airbags with the vehicle doors closed
and the side windows open.
S Deploy the airbags only in an evacuated area. Ser-
vice personnel who must be present during the de-
ployment should be at least 10 meters(33 feet) in
front of the vehicle.
S Do not connect the voltage source until after having
completed all other preparations for the deployment
of airbags.
S Allow a deployed airbag module or pretensioner
cool for 30 minutes before handling.
S Wear gloves and eye protection during the disposal
procedure.
S If the deployment fails, disconnect the voltage
source and wait 5 minutes before approaching the
vehicle.

8B – 96ISUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
DAEWOO V–121 BL4
Deployment Procedure
CAUTION : The sensing and diagnostic mod-
ule(SDM) can maintain sufficient voltage to
deploy the airbags and pretensioners for 1 min-
ute after the ignition is OFF and the fuse has been
removed. If the airbags and pretensioners are not
disconnected, do not begin service until one
minute has passed after disconnecting power to
SDM. If the airbags are disconnected, service can
be executed immediately without waiting for
one–minute time period to expire. Failure to tem-
porarily disable the SIR during service can result
in unexpected deployment, personal injury and
unnecessary SIR repairs.
1. Disconnect both battery cables and place the bat-
tery at least 10 meters (33 feet) from the vehicle.
2. Remove the driver side knee bolster or instrument
panel lower cover from the steering column. Refer
to Section 9G, Interior Trim.
3. At the lower steering column, cut the two wires
leading from the supplemental inflatable re-
straints(SIR) harness to the clock spring.
4. Strip 13mm(0.5 inch) of the insulation from the end
of the wires leading to the clock spring.
5. Use two additional wires, each at least 10 me-
ters(33 feet) long, to reach from the deployment
battery to the inflator module.
6. Strip 13mm(0.5 inch) of the insulation from the end
of these two additional wires.
7. Twist the two wires together at one end.
8. Place the twisted ends of the two wires near the
deployment battery. Do not connect the wires to the
battery at this time.
9. Using the free ends of the 10 meters(33 feet) wires
leading to the clock spring, make two splices, one
at each wires from the airbag modules.
10. Wrap the wires with insulation tape.
11. Now that the free ends of the 10 meters(33 feet)
wires are spliced to the airbag module wires, and
the ends that are twisted together are near the de-
ployment battery. Clear the area.
12. Untwist the wires that near the deployment battery.
13. Touch one wire to the positive battery terminal and
touch the other wire to the negative battery termi-
nal. The airbag will deploy.
14. Repeat this procedure for the passenger airbag,
side airbags and pretensioners.
15. Using proper precautions, dispose of the deployed
airbags/pretensioners. Refer to ”Deployed Airbag
Module Disposal Procedure” in this section.

SECTION : 9A
BODY WIRING SYSTEM
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool
or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help
prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
TABLE OF CONTENTS
SCHEMATIC AND ROUTING DIAGRAMS9A–1 . . . . .
Wire Color Chart 9A–1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Distribution Schematic 9A–3. . . . . . . . . . . . . . .
Fuse Block Locator (Engine) 9A–12. . . . . . . . . . . . . . .
Fuse Block Locator (Passenger Compartment) 9A–12
Fuse Chart 9A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Harness Routing 9A–15. . . . . . . . . . . . . . . . . . . .
Rear Harness Routing 9A–16. . . . . . . . . . . . . . . . . . . . .
Hatchback Rear Harness Routing 9A–17. . . . . . . . . . .
Floor Harness Routing 9A–18. . . . . . . . . . . . . . . . . . . .
Instrument Harness Routing 9A–19. . . . . . . . . . . . . . . .
Door Harness Routing 9A–20. . . . . . . . . . . . . . . . . . . . .
SCHEMATIC AND ROUTING DIAGRAMS
WIRE COLOR CHART
Wire ColorAbbreviation On Schematic
GreenDK GRN
Light GreenLT GRN
BlueDK BLU
BrownBRN
OrangeORN
YellowYEL
GreyGRY
Sky BlueLT BLU
RedRED
BlackBLK
PinkPNK
WhiteWHT
PurplePPL

9A – 2IBODY WIRING SYSTEM
DAEWOO V–121 BL4
Wires With Tracers
Wire ColorAbbreviation On Schematic
Red with White TracerRED/WHT
Red with Black TracerRED/BLK
Brown with White TracerBRN/WHT
Black with White TracerBLK/WHT
Black with Yellow TracerBLK/YEL
Green with Black TracerDK GRN/BLK
Green with White TracerDK GRN/WHT
Light Green with Black TracerLT GRN/BLK
Red with Yellow TracerRED/YEL
Red with Blue TracerRED/DK BLU
Black with Brown TracerBLK/BRN

9C – 4IHORN(S)
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
HORN(S)
The horns are located under the hood. They are attached
near the radiator at the front of the vehicle. The horns are
actuated by pressing the steering wheel pad, which
grounds the horns’ electrical circuit.

9I – 6IWATERLEAKS
DAEWOO V–121 BL4
8. Allow the primer to dry for 5 minutes.
9. Apply the adhesive over the leak and for a distance
of 75 to 100 mm (3 to 4 inches) on both sides of the
leak.
10. Immediately after applying the adhesive, use a flat
stick or a similar tool to work the adhesive into the
leak area and into the joint between the original ma-
terial and the vehicle body in order to ensure a wa-
tertight seal.
11. Spray warm or hot water over the repaired area in
order to determine if the leak was repaired. Do not
run a heavy stream of water directly on the freshly
applied adhesive.
12. Install the trim strip lace if it was removed.
13. Install the garnish molding if it was removed.
14. Install the reveal molding.
Important : After the completion of any waterleak repair,
retest the area using the watertest stands. Do not use
localized testing procedures on the newly–repaired areas,
as the repair material may dislodge under abnormal pres-
sure.

9P – 22IDOORS
DAEWOO V–121 BL4
DOOR LOCK STRIKER ADJUSTMENT
(Front Door Shown, Rear Door Similar)
The door lock striker consists of a striker with two screws
that are threaded into a tapped, floating cage plate located
in the appropriate body pillar. This floating cage plate al-
lows the striker to be easily adjusted in and out or up and
down.
The door is secured in the closed position when the door
lock fork snaps over and engages the striker.
Notice : The door lock striker is an important attaching
part that can affect the performance of vital components
and systems. It can cause major repair expenses. If re-
placement becomes necessary, the door lock striker must
be replaced by one with the same part number or with an
equivalent. Do not use a replacement part of lesser quality
or of a substitute design. The specified torque values must
be used during reassembly to ensure the proper retention
of the part.
Up/Down or In/Out Adjustment
An adjustment of the striker in the up and down or in and
out directions may be necessary for a number of reasons:
S Vehicle frame damage as the result of a collision.
S Installation of new door weatherstripping.
S Customer complaints of excessive windnoise.
S Difficulty in opening or closing the door.
To adjust the door striker in an up and down or in and out
direction, perform the following procedure:
1. The door must be properly aligned.
2. Loosen the striker screws.
3. The floating cage plate can be moved slightly using
the ends of the striker screws. Move the floating
cage plate to the desired position.
4. If proper adjustment requires that the floating cage
plate be moved more than is possible, use an elec-
tric hand drill and a 3/8–inch rotary file bit with a flat
head to enlarge the body opening in the direction
required.
Notice : It is important to use a flat–tipped drill bit to pre-
vent damage to the tapped floating cage plate. The striker
screws and the tapped floating cage plate are important
attaching parts that could affect the performance of vital
components and systems.
5. Tighten the door lock striker screws to the correct
position.
Tighten
Tighten the door lock striker screws to 24 NSm (18 lb–
ft).

SECTION : 9R
BODY FRONT END
TABLE OF CONTENTS
SPECIFICATIONS9R–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 9R–1. . . . . . . . . . .
MAINTENANCE AND REPAIR9R–2 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 9R–2. . . . . . . . . . . . . . . . . . . . .
Lubrication 9R–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fasteners 9R–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anticorrosion Materials 9R–2. . . . . . . . . . . . . . . . . . . . .
Front End Sealing 9R–2. . . . . . . . . . . . . . . . . . . . . . . . .
Cowl Vent Grille 9R–2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood 9R–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood Hinges 9R–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood Prop Rod 9R–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood Secondary Latch 9R–4. . . . . . . . . . . . . . . . . . . . .
Hood Latch Release Cable 9R–5. . . . . . . . . . . . . . . . . .
Notchback Radiator Grille 9R–5. . . . . . . . . . . . . . . . . . .
Hatchback Radiator Grille 9R–6. . . . . . . . . . . . . . . . . . .
Front Wheel Well Splash Shield 9R–6. . . . . . . . . . . . .
Fender 9R–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION9R–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body Front End 9R–10. . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
A–Pillar Fender Bolt10–89
Fender Bolt (Front of Fascia)4–35
Front Bumper Fascia–to–Fender Bolt2.5–22
Hinge Bolts2720–
Hood–to–Hinge Bolts2720–
Hood Latch Bolts8–71
Hood Release Handle Nuts4–35
Lower Fender Bolt10–89
Radiator Grille Nuts4–35
Splash Shield screws2–18
Upper Fender Bolts10–89

9R – 4IBODY FRONT END
DAEWOO V–121 BL4
Installation Procedure
Notice : Dissimilar metals in direct contact with each other
may corrode rapidly. Make sure to use the correct fasten-
ers to prevent premature corrosion.
1. Install the hinge with the bolts.
Tighten
Tighten the hinge bolts to 27 NSm (20 lb–ft).
2. Install the hood. Refer to ”Hood” in this section.
HOOD PROP ROD
Removal Procedure
1. Support the hood in the open position.
2. Remove the hood prop rod by gently prying the
base from the radiator support.
Installation Procedure
1. Install the hood prop rod by snapping the base back
into the radiator support.
HOOD SECONDARY LATCH
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Removal Procedure
1. Open the hood.
2. Mark the position of the hood latch on the radiator
support to facilitate alignment during installation.
3. Remove the bolts and the hood latch.

BODY FRONT END 9R – 5
DAEWOO V–121 BL4
Installation Procedure
Notice : Dissimilar metals in direct contact with each other
may corrode rapidly. Make sure to use the correct fasten-
ers to prevent premature corrosion.
1. Position the hood latch in the location marked dur-
ing removal.
2. Install the hood latch with the bolts.
Tighten
Tighten the hood latch bolts to 8 NSm (71 lb–in).
HOOD LATCH RELEASE CABLE
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Removal Procedure
1. Remove the screws and the hood release handle
from the instrument panel.
2. Open the hood.
3. Remove the bolts and the hood latch release.
4. Remove the cable from the hood latch release as-
sembly.
5. Remove the cable from the engine compartment.
Installation Procedure
Notice : Dissimilar metals in direct contact with each other
may corrode rapidly. Make sure to use the correct fasten-
ers to prevent premature corrosion.
1. Install the radiator grille with the screws.
2. Install the cable into the hood latch release handle.
3. Install the hood release handle on the instrument
panel with the screws.
Tighten
Tighten the hood release handle screws to 4 NSm (35
lb–in).
4. Install the cable to the hood latch release assembly.
5. Install the hood latch release assembly with the
bolts.
Tighten
Tighten the hood latch bolts to 8 NSm (71 lb–in).
NOTCHBACK RADIATOR GRILLE
Removal Procedure
1. Open the hood.
2. Remove the screws and clips at lower area of the
radiator grille.